Calibrated yarn tensioner, textile machine, and method for tensioning a continuously running yarn

ABSTRACT

An adjustable yarn tensioner includes a housing, first and second opposing yarn engaging surfaces, and a tension control assembly for controlling a degree of frictional force applied by the yarn engaging surfaces to a continuously running yarn. The housing has a yarn guiding inlet for receiving the running yarn at an unwinding tension from a yarn supply source, and a yarn guiding outlet for guiding the running yarn exiting the housing at a delivery tension. The first and second yarn engaging surfaces are disposed between the inlet and the outlet of the housing. At least one of the yarn engaging surfaces is adjustably biased towards the other to frictionally engage opposite sides of the running yarn along a path of yarn travel through the housing. The tension control assembly enables a plurality of user-selected graduated tension settings within a tension range greater than 800 grams, and respective tension settings have positive or negative increments of less than 20 grams.

TECHNICAL FIELD AND BACKGROUND

The present disclosure relates broadly and generally to the textile industry, and more particularly to a calibrated yarn tensioner, textile machine, and method for tensioning a continuously running yarn; and in one exemplary embodiment, to a pot-yarn tensioning device in a direct-cabling textile machine. Direct cabling is a common yarn processing technique in the formation of high-quality pile during the manufacture of rugs and carpets. According to this process, two yarns are twisted around each other in a single operation without the individual strands themselves being twisted.

SUMMARY OF EXEMPLARY EMBODIMENTS

Various exemplary embodiments of the present invention are described below. Use of the term “exemplary” means illustrative or by way of example only, and any reference herein to “the invention” is not intended to restrict or limit the invention to exact features or steps of any one or more of the exemplary embodiments disclosed in the present specification. References to “exemplary embodiment,” “one embodiment,” “an embodiment,” “various embodiments,” and the like, may indicate that the embodiment(s) of the invention so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment,” or “in an exemplary embodiment,” do not necessarily refer to the same embodiment, although they may.

It is also noted that terms like “preferably”, “commonly”, and “typically” are not utilized herein to limit the scope of the claimed invention or to imply that certain features are critical, essential, or even important to the structure or function of the claimed invention. Rather, these terms are merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present invention.

According to one exemplary embodiment, the present disclosure comprises an adjustable yarn tensioner including a housing, first and second opposing yarn engaging surfaces, and means for controlling a degree of frictional force applied by the yarn engaging surfaces to a continuously running yarn. The housing has a yarn guiding inlet for receiving the running yarn at an unwinding tension from a yarn supply source, and a yarn guiding outlet for guiding the running yarn exiting the housing at a delivery tension. The first and second yarn engaging surfaces are disposed between the inlet and the outlet of the housing. At least one of the yarn engaging surfaces is adjustably biased towards the other to frictionally engage opposite sides of the running yarn along a path of yarn travel through the housing. The means (“tension control means”) comprises a plurality of user-selected graduated tension settings within a tension range greater than 800 grams, and wherein respective tension settings comprise positive or negative increments of less than 20 grams.

The term “housing” refers broadly herein to any open, closed, or partially open or partially closed structure.

According to another exemplary embodiment, the first yarn engaging surface is substantially convex.

According to another exemplary embodiment, the first yarn engaging surface is freely rotatable along the path of yarn travel through the housing.

According to another exemplary embodiment, the second yarn engaging surface is substantially concave.

According to another exemplary embodiment, the second yarn engaging surface comprises a plurality of fixed arcuately-spaced cylindrical pins. The cylindrical pins may be sequentially spaced. The term “sequentially spaced” is defined herein to mean the physical and/or temporal spacing of elements or structure from upstream to downstream along or adjacent the path of yarn travel.

Use of the terms “upstream” and “downstream” refer herein to relative locations (or movement) of elements or structure to other elements or structure along or adjacent the path of yarn travel. In other words, a first element or structure which is encountered along or adjacent the path of yarn travel before a second element or structure is considered to be “upstream” of the second element or structure, and the second element structure is considered to be “downstream” of the first.

According to another exemplary embodiment, the tension control means comprises a hand-rotatable tensioning dial with an attached elongated threaded shaft. The threaded dial shaft receives a movable bearing plate through a complementary threaded opening formed with the bearing plate. At least one compression spring is located between the bearing plate and the second yarn engaging surface. Rotation of the tensioning dial causes the bearing plate to move along the dial shaft, thereby adjusting a biasing force of the compression spring and controlling the degree of frictional force applied by the first and second yarn engaging surfaces to the running yarn.

According to another exemplary embodiment, the dial shaft defines a circumferential arrangement of spaced dimples formed between the tensioning dial and thread. The dimples cooperate with a spring-biased ball to hold the tensioning dial in a selected fixed position during operation of the yarn tensioner. In the exemplary embodiment, the dimples are formed in the body (or shank) of the threaded dial shaft.

In another exemplary embodiment, the disclosure comprises an adjustable yarn tensioner including a housing, a friction roller rotatably mounted within the housing, a spring-biased friction block mounted within the housing proximate the friction roller, and means (“tension control means”) for controlling a degree of frictional force applied by yarn engaging surfaces of the friction roller and friction block to a continuously running yarn. The tensioner housing has a yarn guiding inlet for receiving the running yarn at an unwinding tension from a yarn supply source, and a yarn guiding outlet for guiding the running yarn exiting the housing at a delivery tension. The friction roller has a circumferential portion defining a first yarn engaging surface. The spring-biased friction block has a generally concave side wall defining a second yarn engaging surface. The first and second yarn engaging surfaces are adapted to frictionally engage opposite sides of the running yarn along a path of yarn travel through the housing. The tension control means comprises a plurality of user-selected graduated tension settings for selectively urging the spring-biased friction block towards the friction roller.

According to another exemplary embodiment, a plurality of fixed arcuately-spaced cylindrical pins are carried by the friction block at the second yarn engaging surface.

According to another exemplary embodiment, the friction roller has a beveled face.

According to another exemplary embodiment, a thumb handle is adapted for manually moving the spring-biased friction block away from the friction roller.

In yet another exemplary embodiment, the present disclosure comprises a textile machine which incorporates an adjustable yarn tensioner according to the various exemplary embodiments described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The description of exemplary embodiments proceeds in conjunction with the following drawings, in which:

FIG. 1 is an environmental perspective view of a calibrated yarn tensioner according to one exemplary embodiment of the present disclosure;

FIG. 2 is a further perspective view of the exemplary yarn tensioner;

FIG. 3 is a front view of the exemplary yarn tensioner;

FIG. 4 is a top view of the exemplary yarn tensioner;

FIG. 5 is a bottom view of the exemplary yarn tensioner;

FIG. 6 is a back view of the exemplary yarn tensioner; and

FIG. 7 is a fragmentary, exploded view of the exemplary yarn tensioner.

DESCRIPTION OF EXEMPLARY EMBODIMENTS AND BEST MODE

The present invention is described more fully hereinafter with reference to the accompanying drawings, in which one or more exemplary embodiments of the invention are shown. Like numbers used herein refer to like elements throughout. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be operative, enabling, and complete. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present invention.

Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Unless otherwise expressly defined herein, such terms are intended to be given their broad ordinary and customary meaning not inconsistent with that applicable in the relevant industry and without restriction to any specific embodiment hereinafter described. As used herein, the article “a” is intended to include one or more items. Where only one item is intended, the term “one”, “single”, or similar language is used. When used herein to join a list of items, the term “or” denotes at least one of the items, but does not exclude a plurality of items of the list.

For exemplary methods or processes of the invention, the sequence and/or arrangement of steps described herein are illustrative and not restrictive. Accordingly, it should be understood that, although steps of various processes or methods may be shown and described as being in a sequence or temporal arrangement, the steps of any such processes or methods are not limited to being carried out in any particular sequence or arrangement, absent an indication otherwise. Indeed, the steps in such processes or methods generally may be carried out in various different sequences and arrangements while still falling within the scope of the present invention.

Additionally, any references to advantages, benefits, unexpected results, or operability of the present invention are not intended as an affirmation that the invention has been previously reduced to practice or that any testing has been performed. Likewise, unless stated otherwise, use of verbs in the past tense (present perfect or preterit) is not intended to indicate or imply that the invention has been previously reduced to practice or that any testing has been performed.

Referring now specifically to the drawings, a calibrated yarn tensioner according to one exemplary embodiment of the present invention is illustrated in FIG. 1, and shown generally at reference numeral 10. The exemplary yarn tensioner is located inside a spindle pot 11 between an upstream yarn feed (or “supply”) package 12 and a downstream textile machine—indicated schematically at 14. The textile machine 14 may be a conventional direct-cabling machine used to form high-quality pile in the manufacture of rugs and carpets.

In a direct-cabling machine, the feed package 12 is loaded into the spindle pot 11 and the yarn “Y” unwound and tensioned using a tensioning device or “yarn-brake”, such as the present tensioner 10. The tensioner 10 may be suspended above the package 12 inside the spindle pot 11 by mounting bracket 15 or other suitable structure. The mounting bracket 15 has a yarn eyelet 16 upstream of the tensioner 10, and longitudinally aligned with an annular opening 18 formed with a top wall of the pot 11 downstream of the tensioner 10. A second feed package (not shown) is loaded into a creel, unwound, and tensioned slightly before it enters a lower hollow shaft of the spindle. This yarn end wraps around a storage disc and forms a balloon around the pot package. At the balloon apex, both yarns meet and wrap around each other, which thus dissolves the false twist in the balloon yarn. At the meeting point, both yarns should have substantially the same tension in order to form a balanced composite yarn with no residual torque and equal lengths of component yarns. Consequently, whenever the spindle speed is altered, the pot-yarn tension should be adjusted to compensate for a consequent increase or decrease in balloon tension. Exemplary embodiments of the present tensioner 10, described below, comprise means for precisely setting and adjusting the pot-yarn tension. In alternative applications, the yarn tensioner 10 may also be used in the creel on the cabler, in other types of creels, and in other various textile machines and processes.

As shown in FIGS. 1-5, the exemplary tensioner 10 comprises a generally open-structure housing 20 having a yarn guiding inlet 21 for receiving running yarn “Y” entering the housing 20 through bracket eyelet 16 at an unwinding tension from the feed package 12, and a yarn guiding outlet 22 for guiding the running yarn “Y” exiting the housing 20 at a delivery (or cabling) tension through pot opening 18. As yarn is pulled from the feed package 12, the yarn tensioner 10 interposed between the package 12 and downstream textile machine 14 applies predetermined frictional resistance to the running yarn “Y”, such that the delivery tension is maintained at a generally uniform, constant and predictable level.

Referring to FIGS. 2, 3, and 7, the exemplary tensioner 10 incorporates a steel friction roller 31 rotatably mounted within the housing 20, and an adjustable spring-biased metal friction block 32. The rotatable friction roller 31 has a circumferential portion defining a first, substantially convex, yarn engaging surface 31A. The adjustable friction block 32 has a generally concave side wall opposite the yarn engaging roller surface 31A, and including a plurality of arcuately-spaced cylindrical ceramic pins 33. The cylindrical pins 33 are fixedly mounted (e.g., glued) within respective elongated sockets 34 formed with the friction block 32, and collectively define a second yarn engaging surface 32A complementary to the curved continuous surface 31A of the friction roller 31. The first and second yarn engaging surfaces 31A, 32A cooperate to frictionally engage opposite sides of the running yarn along a generally arcuate path of yarn travel through a center of the housing 20. In the exemplary embodiment, each cylindrical pin 33 is mounted such that an approximate 90-degree circumferential portion projects from the concave side wall of the friction block 32 towards the friction roller 31. As such, the interrupted surface 32A defined by spaced pins 33 cooperates with the continuous surface 31A of the friction roller 31 to create sequentially-spaced uniform pinch points on the running yarn. An adjustable tension control assembly (or “means”), described below, functions to set and maintain a precise operator-determined amount of frictional force on the running yarn, thereby controlling the delivery tension of pot yarn exiting the housing 20.

As best shown in FIGS. 3 and 7, the adjustable tension control assembly comprises a hand-rotatable tensioning dial 41 with an attached externally threaded shaft 42. The threaded dial shaft 42 receives a movable bearing plate 43 through a complementary threaded plate opening 44. The bearing plate 43 is actuated upon rotation of the threaded dial shaft 42 and moves linearly along guide rods 45, 46 extending between a housing end wall 47 and the adjustable friction block 32. The guide rods 45, 46 reside on opposite sides of the dial shaft 42, and pass freely though respective rod holes 48, 49 formed with the bearing plate 43. Respective compression springs 51, 52 are applied to the guide rods 45, 46 on a block-side of the bearing plate 43, and function to normally urge (or bias) the friction block 32 into yarn-tensioning engagement with the rotatable friction roller 31. Manual rotation of the tensioning dial 41 causes the bearing plate 43 to move linearly along the dial shaft 42, as indicated by direction arrow 48 in FIG. 3, thereby adjusting the collective biasing force of the compression springs 51, 52 on the friction block 32 and controlling the degree of frictional force applied by the first and second yarn engaging surfaces 31A, 32A to the running yarn.

To facilitate initial loading of the pot-yarn in the tensioner 10, the face 61 of the rotatable friction roller 31 may be generally beveled. Additionally, a U-shaped thumb handle 62 may be attached to the friction block 32 allowing the block 32 to be readily pulled away from the friction roller 31, as indicated by direction arrow 64 in FIG. 3, against the biasing force of the compression springs 51, 52, thereby creating space between the yarn engaging surfaces 31A, 32A.

As indicated previously, frictional resistance on the running yarn is adjusted in the present tensioner 10 by manually rotating the tensioning dial 41 to a selected tension setting. The various tension settings are identified by course adjustment markings 71 (e.g., 1-6) applied to the housing 20, and fine adjustment markings 72 (e.g., 0.0-0.9) applied circumferentially around the dial 41. The exemplary tensioner 10 includes 50 numbered available settings within a graduated tension range of approximately 225-1350 grams. Each numbered setting adjusts the yarn tension in positive or negative increments of approximately 16 grams. Upon rotation of the tensioning dial 41, the bearing plate 43 moves linearly along the threaded dial shaft 42 and includes a line marking 73 which aligns with the numbered markings 71 on the housing 20 to indicate the course adjustment setting of the tensioner 10. The fine adjustment marking 72 is displayed through a window 74 formed with a protective plate 75 attached to the housing 20 adjacent the tensioning dial 41.

As shown in FIG. 7, graduation of the tensioner 10 may be determined (in part) by a circumferential arrangement of spaced dimples 81 formed with a neck 82 of the tensioning dial 41 and a spring-loaded steel ball 82. The dimples 81 are matched to the numbered fine adjustment markings 72 on the tensioning dial 41. As the operator rotates the tensioning dial 41 thereby actuating the bearing plate 43, the steel ball 82 moves into and out of the dimples 81 until the desired course and fine tension setting is reached, at which point the spring-loaded ball 82 seats within a dimple 81 cooperates with the dimple 81 to maintain the tensioner 10 at a precise level of frictional resistance on the running yarn.

For the purposes of describing and defining the present invention it is noted that the use of relative terms, such as “substantially”, “generally”, “approximately”, and the like, are utilized herein to represent an inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. These terms are also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.

Exemplary embodiments of the present invention are described above. No element, act, or instruction used in this description should be construed as important, necessary, critical, or essential to the invention unless explicitly described as such. Although only a few of the exemplary embodiments have been described in detail herein, those skilled in the art will readily appreciate that many modifications are possible in these exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention. 

1. An adjustable yarn tensioner, comprising: a housing having a yarn guiding inlet for receiving a continuously running yarn at an unwinding tension from a yarn supply source, and a yarn guiding outlet for guiding the running yarn exiting said housing at a delivery tension; first and second opposing yarn engaging surfaces disposed between said inlet and said outlet, and at least one of said yarn engaging surfaces being adjustably biased towards the other to frictionally engage opposite sides of the running yarn along a path of yarn travel through said housing; and means for controlling a degree of frictional force applied by said yarn engaging surfaces to the running yarn, and comprising a plurality of user-selected graduated tension settings within a tension range greater than 800 grams, and wherein respective tension settings comprise positive or negative increments of less than 20 grams.
 2. An adjustable yarn tensioner according to claim 1, wherein said first yarn engaging surface is substantially convex.
 3. An adjustable yarn tensioner according to claim 2, wherein said first yarn engaging surface is freely rotatable along the path of yarn travel through said housing.
 4. An adjustable yarn tensioner according to claim 3, wherein said second yarn engaging surface is substantially concave.
 5. An adjustable yarn tensioner according to claim 4, wherein said second yarn engaging surface comprises a plurality of fixed arcuately-spaced cylindrical pins.
 6. An adjustable yarn tensioner according to claim 1, wherein said means comprises a hand-rotatable tensioning dial with an attached elongated threaded shaft, a movable bearing plate defining a complementary threaded opening receiving said dial shaft, and at least one compression spring located between said bearing plate and said second yarn engaging surface, whereby rotation of said tensioning dial causes said bearing plate to move along said dial shaft thereby adjusting a biasing force of said compression spring and controlling the degree of frictional force applied by said first and second yarn engaging surfaces to the running yarn.
 7. An adjustable yarn tensioner according to claim 6, wherein said dial shaft defines a circumferential arrangement of spaced dimples formed between said tensioning dial and thread, and said dimples cooperating with a spring-biased ball to hold said tensioning dial in a selected fixed position.
 8. An adjustable yarn tensioner, comprising: a housing having a yarn guiding inlet for receiving a continuously running yarn at an unwinding tension from a yarn supply source, and a yarn guiding outlet for guiding the running yarn exiting said housing at a delivery tension; a friction roller rotatably mounted within said housing, and having a circumferential portion defining a first yarn engaging surface; a spring-biased friction block mounted within said housing proximate said friction roller, and having a generally concave side wall defining a second yarn engaging surface; said first and second yarn engaging surfaces adapted to frictionally engage opposite sides of the running yarn along a path of yarn travel through said housing; and means for controlling a degree of frictional force applied by said first and second yarn engaging surfaces to the running yarn, and comprising a plurality of user-selected graduated tension settings for selectively urging said friction block towards said friction roller.
 9. An adjustable yarn tensioner according to claim 8, and comprising a plurality of fixed arcuately-spaced cylindrical pins carried by said friction block at said second yarn engaging surface.
 10. An adjustable yarn tensioner according to claim 8, wherein said means comprises a hand-rotatable tensioning dial with an attached elongated threaded shaft, a movable bearing plate defining a complementary threaded opening receiving said dial shaft, and at least one compression spring located between said bearing plate and said friction block, whereby rotation of said tensioning dial causes said bearing plate to move along said dial shaft thereby adjusting a biasing force of said compression spring on said friction block and controlling the degree of frictional force applied by said first and second yarn engaging surfaces to the running yarn.
 11. An adjustable yarn tensioner according to claim 10, wherein said dial shaft defines a circumferential arrangement of spaced dimples formed between said tensioning dial and thread, and said dimples cooperating with a spring-biased ball to hold said tensioning dial in a selected fixed position.
 12. An adjustable yarn tensioner according to claim 8, wherein said friction roller has a beveled face.
 13. An adjustable yarn tensioner according to claim 8, and comprising a thumb handle for manually moving said spring-biased friction block away from said friction roller.
 14. In combination with a textile machine, an adjustable yarn tensioner comprising: a housing having a yarn guiding inlet for receiving a continuously running yarn at an unwinding tension from a yarn supply source, and a yarn guiding outlet for guiding the running yarn exiting said housing at a delivery tension; first and second opposing yarn engaging surfaces disposed between said inlet and said outlet, and at least one of said yarn engaging surfaces being adjustably biased towards the other to frictionally engage opposite sides of the running yarn along a path of yarn travel through said housing; and means for controlling a degree of frictional force applied by said yarn engaging surfaces to the running yarn, and comprising a plurality of user-selected graduated tension settings within a tension range greater than 800 grams, and wherein respective tension settings comprise positive or negative increments of less than 20 grams.
 15. A combination according to claim 14, wherein said first yarn engaging surface is substantially convex.
 16. A combination according to claim 15, wherein said first yarn engaging surface is freely rotatable along the path of yarn travel through said housing.
 17. A combination according to claim 16, wherein said second yarn engaging surface is substantially concave.
 18. A combination according to claim 17, wherein said second yarn engaging surface comprises a plurality of fixed arcuately-spaced cylindrical pins.
 19. A combination according to claim 14, wherein said means comprises a hand-rotatable tensioning dial with an attached elongated threaded shaft, a movable bearing plate defining a complementary threaded opening receiving said dial shaft, and at least one compression spring located between said bearing plate and said second yarn engaging surface, whereby rotation of said tensioning dial causes said bearing plate to move along said dial shaft thereby adjusting a biasing force of said compression spring and controlling the degree of frictional force applied by said first and second yarn engaging surfaces to the running yarn.
 20. A combination according to claim 19, wherein said dial shaft defines a circumferential arrangement of spaced dimples formed between said tensioning dial and thread, and said dimples cooperating with a spring-biased ball to hold said tensioning dial in a selected fixed position. 